Apparatus for making condensers



June 12, 1962 J. F. RILEY APPARATUS FOR MAKING CONDENSERS Original FiledAug. 1'7, 1950 2 Sheets-Sheet 1 June 12, 1962 J. F. RILEY 3,038,242

APPARATUS FOR MAKING CONDENSERS Original Filed Aug. 1'7, 1950 2Sheefs-Sheet 2 United States Patent 3,038,242 APPARATUS FOR MAKINGCONDENSERS Joseph F. Riley, Chicago, Ill., assignor, by meme assigrnments, to P. R. Mallory & Co. Inc, Indianapolis, Ind,

a corporation of Delaware Original application Aug. 17, 1950, Ser. No.180,003. Divided and this application Mar. 22, 1954, Ser. No.

6 Claims. (Cl. 29-2542) This invention relates to apparatus for, and amethod of making condensers.

This application is a division of my co-pending application Serial No.180,003, filed August 17, 1950, now abandoned.

One feature of the invention is that it provides a novel and improvedmethod of making condensers; another feature of the invention is that itprovides improved apparatus for making condensers; a further feature ofthe invention is that it provides a method whereby a plurality ofcondenser body members are positioned in spaced relationship and leadWires extending from the body members are clamped to form a singleportable assembly with the body members gripped between the wire ends;still another feature of the invention is that a plurality of thegripped members may be dipped simultaneously in a conductive bindingagent, as moltten solder, to coat the ends of the lead wires and theconductive plates of the body members gripped therebetween; yet afurther feature of the'invention is that the assembly may be positioned,while the solder or other binding agent is still liquid, to form aglobule of solder at the junctures of the wires and conductive plates;yet a further feature of the invention is that it provides improvedapparatus for positioning a plurality of condenser body members inspaced, aligned relationship, gripped between lead wires which extendfrom each body member, and removable means for clamping said wires toform a single readily portable assembly having the body members grippedbetween the lead wire ends; an additional feature of the invention isthat the apparatus includes a base having a recess for positioningdisc-shaped condenser body members, guide means for positioning leadwires which extend from said body members, and clamping means forclamping the lead wires to form a readily portable assembly so that aplurality of condensers can be handled as a unit.

Other features and advantages of the invention will be apparent from thefollowing description and from the drawings, in which:

FIG. 1 is a plan view of apparatus constructed in accordance with theinvention having a plurality of condenser body members positionedthereon, portions of the apparatus being broken away. 7

FIG. 2 is a transverse section along the line 2-2 of FIG. 1.

FIG. 3 is a plan view similar to FIG. 1, but showing a different type ofcondenser.

FIG. 4 is a transverse section along the line 44 of FIG. 3.

FIG. 5 is a plan view of the clamped condenser assembly, the centerportion being broken away.

FIG. 6 is a side elevational view similar to FIG. 5.

FIG. 7 is a vertical section along the line 7-7 of FIG. 8, showingonestep in the method.

FIG. 8 is an end elevational view looking from the left of FIG. 7.

FIG. 9 is a fragmentary section illustrating another step in the method;and

FIG. 10 is a perspective of a tray utilized to carry the condensers, aportion of this tray being shown in section in FIG. 9.

In television receivers, communication receivers, and

other electronic apparatus, particularly apparatus operating atrelatively high frequencies, small disc condensers are very frequentlyused. These condensers are advantageous in that they are much smaller inphysical size than paper condensers for a given capacitance. Forexample, a disc condenser having a diameter of inch may have acapacitance of .001 microfarad and a voltage rating of 600 V. DC, and acondenser having a diameter of only 7 inch may include two .001condensers each having a voltage rating of 600 v. DC.

Disc condensers are formed from a thin disc-shaped body member of aceramic or other dielectric material having conductive plates onopposite sides thereof. These plates may comprise a silver coating, andin single unit condensers the coating may be circular with a diameteralmost as great as the diameter of the ceramic disc. In two-unitcondensers, one side of the dielectric disc may have a circular coatingof conductive material to form one common plate, and the other side ofthe dielectric disc may have two spaced plates, each almostsemi-circular in form and separated by a central uncoated strip of thedielectric disc. In manufacturing the condensers a lead wire is solderedto each conductive plate and a protective dielectric sheath is formedover the body member and the ends of the lead wires, usually by aplurality of dips in one or more coating materials.

In the past it has been the practice to handle condensers individuallyduring manufacture, and a skilled worker could make about 3,000condensers a day by this individual handling method. Utilizing myimproved apparatus and following my novel method, it is possible for aworker to make more than 65,000 condensers a day.

Referring now more particularly to the drawings, the apparatus includesmeans for positioning a plurality of condenser body members, this meanscomprising a base having a substantially horizontal supporting surface.In the apparatus illustrated, the base is formed by a wooden block 20having a main body member 21 of steel secured thereto, as by means ofscrews 22, and having a subsidiary body member 23 of steel securedthereto and extending parallel to the main body member 21 and spacedtherefrom. With this construction the supporting surface is in twoseparated portions and includes the surface 21a of the member 21 and thesurface 23a of the member 23. If desired, the base members 21 and 23might be integral so that the supporting surface would be completely ona single part.

An elongated steel strip 25 is secured on the supporting surface portion21a by means of bolts 26 to provide a raised portion extendinglongitudinally of the supporting surface. A plurality of semi-circularpockets 27 are spaced in a straight line along the periphery of the member '25, these pockets opening into the edge or periphery of the member25 and each being adapted to receive a portion of one of the disc-shapedbody members from which the condensers are to be made.

First guide means opposite each pocket may comprise posts 30 which aredriven into openings in the member 23 so that they project above thesupporting surfaceopposite the center of each pocket 27. Each post has avertical slot as shown at 30a in FIG. 1, these slots extending all theway down to the supporting surface 23a. Second guide means opposite eachpocket intermediate the first guide means 30 and the pockets maycomprise similar posts driven into openings in the supporting surface21a of the member 21. As illustrated, instead of a plurality of separateposts, an elongated strip member 32 is driven into an elongated slot inthe surface 21a, the member 32 projecting above the supporting surface21a and having a pair of outer slots 33 and a center slot 34 oppositeeach pocket.

An elongated channel 35, which is rectangular in transverse crosssection and which extends parallel to the periphery of the raised member25, is formed in the main body member 21 intermediate the two guidemeans. A first clamping bar 36 is adapted to seat in the channel withits upper surface flush with the supporting surface portions 21a, 23a.One or more pins 40 projecting upwardly from the channel bottom maycooperate with wells 41 in the clamping bar 36 to hold the bar inposition in the channel. A second clamping bar 42 similar in size andshape to the bar 36 is adapted to seat atop the bar 36, and means on thebars are provided for clamping the bars together. This means maycomprise studs 43 extending through openings in the bar 42 andcooperating with threaded openings in the bar 36.

Because of small variations in the diameter of the lead wires the planesurfaces of the clamping bars can not obtain a good grip upon each leadwire to hold each condenser properly in place. In order to correct this,I provide gripping means comprising an elongated member 44 of springmaterial riveted on the bar 42. As shown in FIGS. 2 and 4 the grippingmember 44 is arcuate in transverse section and is narrower than the bar42, whereby its side edges grip the wires between the bars when the barsare clamped together, thereby compensating for slight inequalities inthe diameter of the lead wire.

In manufacturing condensers a plurality of disc-shaped condenser bodymembers 50 may be positioned on the apparatus, one body member in eachpocket 27. The body members 50 are of ceramic or other dielectricmaterial and have conductive plates 51 on each side thereof. Thecondensers illustrated in FIG. 1 are single unit condensers, and theplates may comprise silver coatings which are circular and are centeredon the dielectric discs, leaving a peripheral dielectric strip. In thetwounit condensers illustrated in FIG. 3, two plates may be provided onone side of each disc, these plates being designated at 51a and 51b, andthe plates being separated by a center strip of the ceramic disc.

Lead wires 53 are placed with their ends engaging each respective plate.In the apparatus of FIG. 1 each lead wire may comprise an elongated loophaving its ends crossed in scissors form, and in positioning condensersas shown, each condenser body member may he slipped between the crossedends of the lead wires so that the lead wire ends engage the respectiveplates, and the condenser assembly may then be positioned on theapparatus with the condenser body member 56 received in the pocket 27and with the lead wires positioned in the outside slots 33 of the guidemeans 32 and extending around the posts 30 which comprise the otherguide means.

FIG. 3 shows a similar arrangement except that the lead wire loops 50have their ends in engagement with the plates 51a and 51b on the sameside of the ceramic disc, and another lead wire 54 may be formed as a Uhaving its ends in engagement with the single plate 51 on the oppositeside of two adjacent condenser body members.

After a condenser has been positioned in each of the pockets 27, thesecond clamping bar 42 may be placed atop the clamping bar 36 and thestuds 43 may be tightened to clamp the two bars together with the leadwires therebetween and form a single readily portable assembly havingthe condenser body members 50 gripped between the lead wire ends. Anyconvenient number of condensers may be handled in such an assembly. Forcondenser discs having a diameter of inch, clamping bars having anover-all length of about 12 inches may be used to hold 21 condensers ata time; or 14 discs having a diameter of /2 inch may be clamped betweenbars of similar length, if desired. Of course, the pockets 27 are formedon an arc of a circle having the same diameter as the discs to bepositioned therein.

After the bars are secured together to clamp the wires and form theportable assembly, the assembly is removed from the base portion and ispositioned with the discs extending downwardly. With the assembly heldin this position, the discs may be dipped in a fluxing agent. FIG. 5shows the clamped assembly after it has been moved out of thepositioning apparatus. The assembly may then be inverted from theposition of FIG. 5 and the discs may all be clipped simultaneously in atank 60 (FIG. 7) having therein a fiuxing agent 61. With the discs inthe same position they may be dipped in molten solder 62 in another tank63 which may be adjacent the flux tank 60 and which preferably has acover 64 with an elongated narrow central opening 65 therein in order toprevent excessive fumes from escaping from the solder tank. The soldercoats only the conductive plates and the lead wire ends and does notstick to the edge portions of the ceramic discs, so the plates are notshorted. The assembly is again inverted while the solder in still liquidso that a globule of solder is formed in the junctures of the lead wiresand the conductive plates 51 to strengthen the solder connection. Aplurality of assemblies may then be placed on a drying rack comprisingspaced holder arms 66 mounted on a wall 67 having a hood 67a and havingan opening connected by a pipe 68 to a source of suction in order toremove fumes from the hot solder. A lip 6717 may be provided so thatflux droppings will fall back in the flux tank. Preferably the solder inthe tank 63 is kept at a temperature of about 400 F. so that the solderremains liquid for a sufiicient time for the operator to invert theassembly and place it on the drying rack.

When the solder has solidified a plurality of the clamped assemblies maybe placed in a tray comprising peripheral angle irons 69 and legs 70,where the discs may be treated with trichloro ethylene vapor fordegreasing the discs, and then may be dipped into polycylopentadenewhich forms a moisture-proof covering. After drying in a blast of hot orcold air, the discs may be dipped in a dielectric mixture, as forexample, a thermosetting resin and mica mixture which forms a heavydielectric sheath over the discs. If desired, at this stage the discsmay be printed with color code symbols, each disc being individuallyprinted in conventional manner. The assembly is then placed in a papercutter and the paper cutter blade is utilized to shear the lead wireloops, the shear line being designated at 71 in FIG. 5. After shearing,the studs 43 may be removed so that the condensers can be taken out ofthe clamping bars and the manufacturing process is completed by handlingthe condensers individually. After removal from the clamping bars,groups of condensers may be dumped in jars ad baked to set the resin.After curing the resin the condensers may be placed in a basket andsubjected to a strong vacuum for about a half hour to remove entrappedair. As a final step in the manufacture the condensers are coated withwax, preferably being left in liquid microcrystalline wax at atemperature of -200 F. for about a half hour to impregnate thedielectric sheath with wax, and the condensers are then dumped andscattered so they will not stick together while they are cooled anddried.

While I have shown and described certain embodiments of my invention, itis to be understood that it is capable of many modifications. Changes,therefore, in the construetion and arrangement may be made withoutdeparting from the spirit and scope of the invention as disclosed in theappended claims.

I claim:

1. Apparatus of the character described for making condensers,comprising: a base having a substantially horizontal supporting surface;an elongated raised portion on said surface having a plurality ofpockets spaced in a line along the periphery thereof, each adapted toreceive a condenser body member; guide means opposite each pocket forpositioning lead wires in contact with but unattached to the oppositesides of each condenser body member; means providing a channel generallyparallel to said raised portion intermediate at least a portion of saidguide means and said pockets, said wires extending across said channel;a first clamping bar adapted to seat in said channel beneath said Wireswith its upper surface substantially flush with said supporting surface;a second clamping bar adapted to cooperate with said first bar to clampsaid wires and form a single readily portable assembly having said bodymembers gripped between the lead wire ends; and gripping meanscomprising an elongated member of spring material mounted on one of saidbars, said gripping means being arcuate in transverse section wherebyits side edges grip said Wires between said bars.

2. Apparatus of the character described for making condensers,comprising: an elongated base having a substantially horizontalsupporting surface; a raised portion extending longitudinally of saidsurface having a plurality of generally semi-circular pockets spaced ina straight line along the periphery thereof, each adapted to receive aportion of a disc-shaped condenser body member; guide means projectingabove the plane of said surface providing means opposite each pocket forpositioning lead wires in contact with but unattached to the oppositesides of each condenser body member; means providing an elongatedchannel rectangular in cross section and extending parallel to theperiphery of said raised portion intermediate at least a portion of saidguide means and said pockets, said wires extending across said channel,a first clamping b-ar adapted to seat in said channel beneath said wireswith its upper surface flush with said supporting surface; a secondclamping bar adapted to seat atop said first bar and Wires; and means onsaid bars for clamping said bars together to clamp said wires and form asingle readily portable assembly having said body members grippedbetween the lead wire ends.

3. Apparatus of the character described for making condensers,comprising: an elongated base having a substantially horizontalsupporting surface; a raised portion extending longitudinally of saidsurface having a plurality of generally semi-circular pockets spaced ina straight line along the periphery thereof, each adapted to receive aportion of a disc-shaped condenser body member; first guide meansopposite each pocket; second guide means opposite each pocketintermediate said first guide means and said pockets, said first andsecond guide means providing a plurality of vertical guides forpositioning lead wires in contact with but unattached to opposite sidesof each condenser body; means pnoviding an elongated channel rectangularin cross section and extending parallel to said raised portionintermediate said first and second guide means, said wires extendingacross said channel, a first clamping bar adapted to seat in saidchannel beneath said wires with its upper surface flush with saidsupporting surface; a second clamping bar adapted to seat atop saidfirst bar and wires; gripping means comprising an elongated member ofspring material mounted on said second bar, said gripping means beingnarrower than said bars and being arcuate in transverse section wherebyits side edges engage said wires between said bars; and means on saidbars for clamping said bars together to clamp said wires and form asingle readily portable assembly having said body members grippedbetween the lead wire ends.

4. Apparatus of the character described for making condensers,comprising: a base having a supporting surface; a raised portion on saidsurface having a plurality of pockets spaced in a line along theperiphery thereof,

each adapted to receive a condenser body member; a post projecting fromsaid supporting surface opposite each pocket, each post having avertical slot therein; second guide means opposite each pocketintermediate said first guide means and said pockets, said first andsecond guide means providing a plurality of vertical guides forpositioning lead 'wires in contact with but unattached to opposite sidesof each condenser body; means providing a channel generally parallel tothe periphery of said raised portion intermediate said first and secondguide means; and a clamping device adapted to seat in said channel toclamp said wires and form a single readily portable assembly having saidbody members gripped between the lead wire ends.

5. Apparatus for assembling condenser components, comprising: a basehaving a substantially horizontal supporting surface; an elongatedraised portion on said surface having a plurality of pockets spaced in aline along the periphery thereof, each adapted to receive a condenserbody member; guide means opposite each pocket for positioning lead wireshaving their ends in opposed contact with but unattached to the oppositesides of each condenser body member; means providing a channel generallyparallel to said raised portion intermediate at least a portion of saidguide means and said pockets, said wires extending across said channel;a first clamping bar removably seated in said channel beneath said wireswith its upper surface substantially flush with said supporting surface;-a second clamping bar cooperating with said first bar to clamp saidwires and force their ends into gripping contact with said condenserbodies and form a single readily portable assembly having said bodymembers gripped between the lead wire ends; said bars including grippingmeans to augment the grip on said Wires, and means to force and holdsaid bars together.

6. Apparatus for assembling condenser components, comprising: anelongated base having a substantially horizontal supporting surface; araised portion extending longitudinally of said surface having aplurality of pockets spaced in a straight line along the peripherythereof, each adapted to receive a portion of a condenser body member;guide means projecting above the plane of said surface providing meansopposite each pocket for positioning lead wires having their ends inopposed contact with but unattached to the opposite sides of eachcondenser body member; means providing an elongated channel extendingparallel to the periphery of said raised portion intermediate at least aportion of said guide means and said pockets, said wires extendingacross said channel, a first clamping bar removably seated in saidchannel beneath said wires with its upper surface flush with saidsupporting surface; a second clamping bar adapted to seat atop saidfirst bar and wires and force their ends into gripping contact with saidcondenser bodies; and means on said bars for clamping said bars togetherto clamp said wires and form a single readily portable assembly havingsaid body members gripped between the lead wire ends.

References Cited in the file of this patent UNITED STATES PATENTS2,606,955 Herrick Aug. 12, 1952 2,693,634 Huyett Nov. 9, 1954 2,766,510Heibel Oct. 16, 1956 FOREIGN PATENTS 535,257 Great Britain Apr. 3, 1941

